Semiconductor Device, Method, and Tool of Manufacture

ABSTRACT

In an embodiment, a method includes: performing a self-limiting process to modify a top surface of a wafer; after the self-limiting process completes, removing the modified top surface from the wafer; and repeating the performing the self-limiting process and the removing the modified top surface from the wafer until a thickness of the wafer is decreased to a predetermined thickness.

PRIORITY CLAIM AND CROSS-REFERENCE

This application claims the benefit of U.S. Provisional Application No.62/471,736, filed on Mar. 15, 2017, which application is herebyincorporated herein by reference.

BACKGROUND

Semiconductor devices are used in a variety of electronic applications,such as, for example, personal computers, cell phones, digital cameras,and other electronic equipment. Semiconductor devices are typicallyfabricated by sequentially depositing insulating or dielectric layers,conductive layers, and semiconductor layers of material over asemiconductor substrate, and patterning the various material layersusing lithography to form circuit components and elements thereon.

The semiconductor industry continues to improve the integration densityof various electronic components (e.g., transistors, diodes, resistors,capacitors, etc.) by continual reductions in minimum feature size, whichallow more components to be integrated into a given area. However, asthe minimum features sizes are reduced, additional problems arise thatshould be addressed.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are best understood from the followingdetailed description when read with the accompanying figures. It isnoted that, in accordance with the standard practice in the industry,various features are not drawn to scale. In fact, the dimensions of thevarious features may be arbitrarily increased or reduced for clarity ofdiscussion.

FIG. 1 illustrates an example of a FinFET in a three-dimensional view,according to some embodiments.

FIGS. 2, 3, 4, 5, 6, and 7 are cross-sectional views of intermediatestages in the manufacturing of FinFETs, according to some embodiments.

FIGS. 8A, 8B, 8C, and 8D illustrate aspects of a planarization system,according to some embodiments.

FIG. 8E illustrates aspects of a planarization system, according to someother embodiments.

FIGS. 9, 10A, 10B, 11A, 11B, 12A, 12B, 13A, 13B, 14A, 14B, 15A, 15B,16A, 16B, 17A, 17B, 18A, and 18B are cross-sectional views ofintermediate stages in the manufacturing of FinFETs, according to someembodiments.

DETAILED DESCRIPTION

The following disclosure provides many different embodiments, orexamples, for implementing different features of the invention. Specificexamples of components and arrangements are described below to simplifythe present disclosure. These are, of course, merely examples and arenot intended to be limiting. For example, the formation of a firstfeature over or on a second feature in the description that follows mayinclude embodiments in which the first and second features are formed indirect contact, and may also include embodiments in which additionalfeatures may be formed between the first and second features, such thatthe first and second features may not be in direct contact. In addition,the present disclosure may repeat reference numerals and/or letters inthe various examples. This repetition is for the purpose of simplicityand clarity and does not in itself dictate a relationship between thevarious embodiments and/or configurations discussed.

Further, spatially relative terms, such as “beneath,” “below,” “lower,”“above,” “upper” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. The spatiallyrelative terms are intended to encompass different orientations of thedevice in use or operation in addition to the orientation depicted inthe figures. The apparatus may be otherwise oriented (rotated 90 degreesor at other orientations) and the spatially relative descriptors usedherein may likewise be interpreted accordingly.

Semiconductor devices, methods, and tools of manufacture are describedin accordance with various embodiments. In particular, a wafer having asemiconductor substrate thereon is placed in a planarization chamber. Inthe planarization chamber, a self-limiting process is performed in afirst step to convert a top surface of the wafer to form a layer or filmof a predetermined thickness. The layer or film has achemical-mechanical planarization (CMP) removal rate several orders ofmagnitude larger than the CMP removal rate of the underlying portions ofthe wafer, and may be referred to as a modified surface layer. Themodified surface layer may be a very thin layer, and in some embodimentsmay have or approach a thickness of a monolayer. As such, embodimentplanarization techniques may be referred to herein as atomic layerremoval (ALR). A removal process is then performed in a second step toremove the formed layer or film.

In some embodiments, the self-limiting process used to form the modifiedsurface layer is a chemically driven oxidation process that weakens thesurface layer. The oxidation process converts a surface of the wafer toan oxide layer or film. The oxidation process may be performed untilsaturation of the oxidation of the surface of the wafer, e.g., until thethickness substantially stops increasing. The thickness of the oxidelayer is self-limiting by nature of the oxidation process; in otherwords, the oxidation process is self-limiting such that the oxidationrate of the wafer surface saturates, e.g., slows substantially or stopson its own. Once saturation occurs, the oxidation process is slowed orstopped. Selecting the parameters of the oxidation process, such as theoxidation reactants, may allow the saturation point (and thus thethickness of the oxidized layer) to be controlled. In an embodiment, thechemically driven oxidation process includes dispensing the oxidationreactants in a liquid form, e.g., as an oxidation solution. For example,the oxidation solution may be dispensed on the wafer using the sameslurry dispenser that is used to dispense slurry during the removalprocess of the CMP. In some embodiments, the self-limiting processincludes chemically bonding the surface layer of the wafer to moleculesintroduced to the wafer surface. The chemical bonding process isself-limiting, and ends when all or a substantial portion of the surfacebonds of the wafer are occupied. A wide variety of bonding chemicals,e.g., ligands, may be used. For example, in some embodiments, thesurface layer of the wafer may be a metal, and a chelator may be used tooccupy the surface bonds of the wafer.

After the self-limiting process is performed to modify the surface layerof the wafer, the removal process is performed to remove the modifiedsurface layer. In an embodiment, the removal process is a mechanicaland/or chemical removal process. During removal, only the modifiedsurface layer may be removed, and substantially no further material maybe removed during the removal process. The surface layer is not furthermodified during the removal process, e.g., no further oxidation orchemical bonding occurs between the end of forming the modified surfacelayer and the end of the removal process. Likewise, no removal may beperformed during the modification of the wafer surface. The CMP removalrate is limited by the thickness of the modified surface layer, which isself-limited by the oxidation or chemical bonding process. Theself-limiting modification process and the removal process may berepeated until a desired amount of material has been removed from thesurface of the wafer.

In accordance with some embodiments, a predefined thickness of materialmay be removed from the wafer by controlling parameters of theself-limited modification process, such as the oxide reactants, and notpolishing the wafer until after the self-limited modification processhas completed to saturation. As such, the time and material costs ofsome techniques used to rework variances of a CMP may be avoided.Finally, use of a planarization stop layer at the desired CMP stoppingpoint may be avoided, further reducing costs.

FIG. 1 illustrates an example of a FinFET in a three-dimensional view,according to some embodiments. The FinFET comprises a fin 58 on asubstrate 50. The substrate 50 includes isolation regions 56, and thefin 58 protrudes above and from between neighboring isolation regions56. A gate dielectric layer 92 is along sidewalls and over a top surfaceof the fin 58, and a gate electrode 94 is over the gate dielectric layer92. Source/drain regions 82 are disposed in opposite sides of the fin 58with respect to the gate dielectric layer 92 and gate electrode 94. FIG.1 further illustrates reference cross-sections that are used in laterfigures. Cross-section A-A is across a channel, gate dielectric layer92, and gate electrode 94 of the FinFET. Cross-section B-B isperpendicular to cross-section A-A and is along a longitudinal axis ofthe fin 58 and in a direction of, for example, a current flow betweenthe source/drain regions 82. Subsequent figures refer to these referencecross-sections for clarity.

Some embodiments discussed herein are discussed in the context ofFinFETs formed using a gate-last process. In other embodiments, agate-first process may be used. Also, some embodiments contemplateaspects used in planar devices, such as planar FETs.

FIGS. 2 through 18B are cross-sectional views of intermediate stages inthe manufacturing of FinFETs, according to some embodiments. FIGS. 2through 7 and 8C through 9 illustrate reference cross-section A-Aillustrated in FIG. 1, except for multiple FinFETs. In FIGS. 10A through18B, figures ending with an “A” designation are illustrated alongreference cross-section A-A illustrated in FIG. 1, and figures endingwith a “B” designation are illustrated along a similar cross-sectionB-B, except for multiple FinFETs.

In FIG. 2, a substrate 50 is provided to form the wafers. The substrate50 may be a semiconductor substrate, such as a bulk semiconductor, asemiconductor-on-insulator (SOI) substrate, or the like, which may bedoped (e.g., with a p-type or an n-type dopant) or undoped. Thesubstrate 50 may be a wafer, such as a silicon wafer. Generally, an SOIsubstrate is a layer of a semiconductor material formed on an insulatorlayer. The insulator layer may be, for example, a buried oxide (BOX)layer, a silicon oxide layer, or the like. The insulator layer isprovided on a substrate, typically a silicon or glass substrate. Othersubstrates, such as a multi-layered or gradient substrate may also beused. In some embodiments, the semiconductor material of the substrate50 may include silicon; germanium; a compound semiconductor includingsilicon carbide, gallium arsenic, gallium phosphide, indium phosphide,indium arsenide, and/or indium antimonide; an alloy semiconductorincluding SiGe, GaAsP, AlInAs, AlGaAs, GalnAs, GaInP, and/or GaInAsP; orcombinations thereof.

The substrate 50 has a first region 50B and a second region 50C. Thefirst region 50B can be for forming n-type devices, such as NMOStransistors, e.g., n-type FinFETs. The second region 50C can be forforming p-type devices, such as PMOS transistors, e.g., p-type FinFETs.In some embodiments, both the first region 50B and the second region 50Care used to form the same type of devices, such as both regions beingfor n-type devices or p-type devices.

In FIG. 3, fins 52 are formed in the substrate 50. The fins 52 aresemiconductor strips. In some embodiments, the fins 52 may be formed inthe substrate 50 by etching trenches in the substrate 50. The etchingmay be any acceptable etch process, such as a reactive ion etch (RIE),neutral beam etch (NBE), the like, or a combination thereof. The etchmay be anisotropic.

In FIG. 4, an insulation material 54 is formed over the substrate 50 andbetween neighboring fins 52. The insulation material 54 may be an oxide,such as silicon oxide, a nitride, the like, or a combination thereof,and may be formed by a high density plasma chemical vapor deposition(HDP-CVD), a flowable CVD (FCVD) (e.g., a CVD-based material depositionin a remote plasma system and post curing to make it convert to anothermaterial, such as an oxide), the like, or a combination thereof. Otherinsulation materials formed by any acceptable process may be used. Inthe illustrated embodiment, the insulation material 54 is silicon oxideformed by a FCVD process. An anneal process may be performed once theinsulation material is formed. In an embodiment, the insulation material54 is formed such that excess insulation material 54 covers the fins 52.

In FIG. 5, a planarization process is performed on the insulationmaterial 54. The planarization process exposes the fins 52. Top surfacesof the fins 52 and the insulation material 54 are level after theplanarization process is complete.

In FIG. 6, the insulation material 54 is recessed to form Shallow TrenchIsolation (STI) regions 56. The insulation material 54 is recessed suchthat fins 58 in the first region 50B and in the second region 50Cprotrude from between neighboring STI regions 56. Further, the topsurfaces of the STI regions 56 may have a flat surface as illustrated, aconvex surface, a concave surface, or a combination thereof. The topsurfaces of the STI regions 56 may be formed flat, convex, and/orconcave by an appropriate etch. The STI regions 56 may be recessed usingan acceptable etching process, such as one that is selective to thematerial of the insulation material 54.

Further in FIG. 6, appropriate wells (not shown) may be formed in thefins 58, the fins 52, and/or the substrate 50. In some embodiments, a Pwell may be formed in the first region 50B, and an N well may be formedin the second region 50C. In some embodiments, a P well or an N well areformed in both the first region 50B and the second region 50C. In theembodiments with different well types, the different implant steps forthe first region 50B and the second region 50C may be achieved using aphotoresist or other masks (not shown), where each region is maskedwhile impurities are implanted in the other region. After the implantsof the first region 50B and the second region 50C, an anneal may beperformed to activate the p-type and/or n-type impurities that wereimplanted.

In FIG. 7, a dummy dielectric layer 60 is formed on the fins 58. Becausevarious embodiments allow use of a planarization stop layer to beavoided, the dummy dielectric layer 60 may physically contact the fins58. The dummy dielectric layer 60 may be, for example, silicon oxide,silicon nitride, a combination thereof, or the like, and may bedeposited or thermally grown according to acceptable techniques. A dummygate layer 62 is formed over the dummy dielectric layer 60. The dummygate layer 62 may be a conductive material and may be selected from agroup including polycrystalline-silicon (polysilicon), poly-crystallinesilicon-germanium (poly-SiGe), metallic nitrides, metallic silicides,metallic oxides, and metals. In one embodiment, amorphous silicon isdeposited and recrystallized to create polysilicon. The dummy gate layer62 may be deposited by physical vapor deposition (PVD), CVD, sputterdeposition, or other techniques known and used in the art for depositingconductive materials. The dummy gate layer 62 may be made of othermaterials that have a high etching selectivity from the etching ofisolation regions. The dummy gate layer 62 may be deposited over thedummy dielectric layer 60 and then planarized, such as by a CMP. In anembodiment, the planarization process used to planarize the dummy gatelayer 62 is an ALR process performed using the planarization system 200.

FIGS. 8A, 8B, 8C, and 8D illustrate a self-limiting planarizationprocess which may be used to planarize the dummy gate layer 62. FIGS.8A, 8B, 8C, and 8D illustrate planarization of the dummy gate layer 62in a self-limiting planarization process using a planarization system200, according to some embodiments. FIGS. 8A and 8B illustrate aspectsof the planarization system 200. FIG. 8C and 8D are cross-sectionalviews of intermediate stages in the manufacturing of the FinFETs usingthe planarization system 200. In FIG. 8C, a self-limiting process isperformed to convert a top surface of the dummy gate layer 62 to amodified surface layer 62S. In FIG. 8D, a removal process is performedto remove the modified surface layer 62S from the dummy gate layer 62.This process is repeated until a predetermined quantity of material hasbeen removed. In the embodiment shown in FIGS. 8A, 8B, 8C, and 8D, theself-limiting process is an oxidation process performed with anoxidation solution forms the modified surface layer 62S by weakening thesurface of the dummy gate layer 62. In other embodiments, a process forchemically bonding the surface layer of the wafer to ligands could beused to form the modified layer or film.

FIGS. 8A and 8B illustrate the planarization system 200. Duringoperation, the substrate 50 is placed on a wafer carrier 201. Theself-limiting process is performed to form the modified surface layer62S in the top surface of the dummy gate layer 62. Once the modifiedsurface layer 62S is formed, a platen 203 may be used to grind thesubstrate 50, thereby removing the modified surface layer 62S. Duringremoval, a CMP slurry 207 may be dispensed through a slurry dispenser205. The CMP slurry 207 may be a slurry that includes abrasives and/oretching chemicals, but does not include oxidizing chemicals. The platen203 may include a polishing pad, and acts as a carrier for abrasives inthe CMP slurry 207.

As part of the self-limiting process, the planarization system 200receives the oxidation reactants from one or more oxidation reactantdelivery systems 211. In an embodiment, the oxidation reactant deliverysystems 211 may work in conjunction with one another to supply thevarious different oxidation reactants to form an oxidation solution thatis dispensed in a planarization chamber 219, wherein the substrate 50 isplaced on the wafer carrier 201. The oxidation reactant delivery systems211 may each have physical components that are similar with each other.

The oxidation reactant delivery systems 211 may each include a chemicalsupply 221 and a flow controller 223. The chemical supply 221 of eachoxidation reactant delivery system 211 may supply the respectiveoxidation reactant to form the oxidation solution that is dispensed inthe planarization chamber 219. Each chemical supply 221 may be a vessel,such as a liquid or gas storage tank, that is located either locally tothe planarization chamber 219 or else may be located remotely from theplanarization chamber 219. Alternatively, each chemical supply 221 maybe a facility that independently prepares and delivers the oxidationreactants to the flow controller 223. Any suitable source for theoxidation reactants may be utilized as the chemical supply 221, and allsuch sources are fully intended to be included within the scope of theembodiments. The flow controller 223 may be, e.g., a proportional valve,a modulating valve, a needle valve, a pressure regulator, a mass flowcontroller, combinations of these, or the like. However, any suitablemethod for controlling and regulating the flow may be utilized, and allsuch components and methods are fully intended to be included within thescope of the embodiments.

The planarization chamber 219 may receive the desired oxidation solutionand expose the surface of the substrate 50 to the oxidation solution.The planarization chamber 219 may be any desired shape that may besuitable for dispersing the oxidation solution and contacting theoxidation solution with the dummy gate layer 62. In the embodimentillustrated, the planarization chamber 219 has a cylindrical sidewalland a bottom. However, the planarization chamber 219 is not limited to acylindrical shape, and any other suitable shape, such as a hollow squaretube, an octagonal shape, or the like, may be utilized. Furthermore, theplanarization chamber 219 may be surrounded by a housing 233 made ofmaterial that is inert to the oxidation solution. As such, while thehousing 233 may be any suitable material that can withstand thechemistries involved in the planarization process, in an embodiment thehousing 233 may be steel, stainless steel, nickel, aluminum, alloys ofthese, combinations of these, and like, and may be covered with aplastic shield. In some embodiments, metal parts of the housing 233 arecoated with a polymer.

The planarization chamber 219 may also have an outlet 237 for exhaustliquids and gases to exit the planarization chamber 219. A pump 239 maybe connected to the outlet 237 of the planarization chamber 219 in orderto help evacuate the processing materials. The pump 239, under controlof the control unit 227, may also be utilized to evacuate oxidationsolution from the planarization chamber 219, in preparation for theintroduction of the next oxidation solution. In some embodiments, theoxidation solution may be purged with a spin-off operation. For example,the oxidation solution may be spun off, the substrate 50 may be rinsedwith water, and the water may then be spun off. The waste water andoxidation solution may be evacuated through the outlet 237.

In FIG. 8C, the self-limiting oxide process is performed in the firststep of the planarization, thereby oxidizing the surface of thesubstrate 50 such that some of the surface of the dummy gate layer 62 isconverted to a modified surface layer 62S. In FIG. 8A, the modifiedsurface layer 62S is an oxide of the dummy gate layer 62, and is formedby increasing the oxygen concentration of the top surface of the dummygate layer 62.

The self-limiting oxidation process is performed by dispensing theoxidation solution on the surface of the dummy gate layer 62. In someembodiments, the oxidation solution is formed by oxidation reactantsthat include water and H₂O₂. The H₂O₂ may be diluted to a concentrationof about 5% of the oxidation solution. In some embodiments, theoxidation solution is ozonated water, e.g., water that ozone has beendissolved in. The oxidation solution may be formed by oxidationreactants that include water and ozone, and the ozone may be dissolvedin the water such that the ozone concentration is about 30 ppm. In someembodiments, the oxidation solution includes Fe(NO₃)₃ (e.g., ferricnitrate). The oxidation reactant delivery systems 211 supply theoxidation reactants to the flow controller 223. The flow controller 223may be utilized to control the flow of the oxidation reactants to anoxidation reactant controller 224 and, eventually, to the planarizationchamber 219 via the slurry dispenser 205. One or more of the oxidationreactant delivery systems 211 may supply their individual oxidationreactants into the oxidation reactant controller 224. The oxidationreactant controller 224 connects and isolates the respective oxidationreactant delivery systems to and from the planarization chamber 219, inorder to deliver the desired oxidation reactants to the slurry dispenser205. The oxidation reactant controller 224 may include devices such asvalves, flow meters, sensors, and the like to control the delivery ratesof each of the oxidation reactants, and may be controlled byinstructions received from a control unit 227 (described further belowwith respect to FIG. 8B). The oxidation reactant controller 224, uponreceiving instructions from the control unit 227, may open and closevalves so as to connect one or more of the oxidation reactant deliverysystems 211 to the planarization chamber 219 and direct a desiredoxidation solution through the slurry dispenser 205. The oxidationsolution may be delivered by the oxidation reactant controller 224 at aflow rate of from about 20 sccm to about 300 sccm, such as about 100sccm. The desired oxidation solution may therefore be applied to thesubstrate 50. In an embodiment, the oxidation solution is applied to thesubstrate 50 before the removal aspect (e.g., the grinding) of the CMPis performed.

The self-limiting oxide process may be performed until oxidization ofthe dummy gate layer 62 is saturated, e.g., until the formation rate ofthe modified surface layer 62S substantially decreases or stops.Saturation may occur, for example, after a predetermined amount of timeelapses, such as from about 1 second to about 30 seconds, such as about3 seconds. Saturation may also occur, for example, after the modifiedsurface layer 62S is formed to a predetermined thickness T₁, such as athickness of from about 2 Å to about 50 Å, such as about 10 Å. In anembodiment, the thickness T₁ is as small as a monolayer. As noted above,the oxide process shown in FIG. 8C is performed before mechanical forcesare applied to the dummy gate layer 62. After the self-limiting oxideprocess completes, and before the modified surface layer 62S is removed,the oxidation solution may be removed with a rinsing and spin-offoperation, as described above.

In FIG. 8D, once delivery of the oxidation solution has been stopped,the removal process is performed in the second step of theplanarization, thereby removing the modified surface layer 62S from thetop surface of the dummy gate layer 62. The removal process may includegrinding the dummy gate layer 62 with the platen 203. The platen 203may, e.g., be rotatably applied to the substrate 50 in order tomechanically grind and remove the modified surface layer 62S. During theremoval process, substantially no further oxidation of the dummy gatelayer 62 occurs. As such, the modified surface layer 62S may notincrease in thickness during removal. The platen 203 may be applied withthe same amount of downward pressure and rotation speed as an oxide CMP.For example, the platen 203 may be applied with a downward pressure ofabout 2 psi, and the platen 203 may be rotated at about 100 RPM.

In order to assist in the removal process, CMP slurry 207 mayadditionally be added to the grinding process of the platen 203 throughthe slurry dispenser 205. The CMP slurry 207 may be provided by one ormore slurry delivery systems 213. The slurry delivery systems 213provide individual chemical components that are mixed to produce the CMPslurry 207. For example, the slurry delivery systems 213 may provideetchants, abrasives, and the like, to produce an abrasive solution. TheCMP slurry 207 may be different from the oxidation solution delivered tothe dummy gate layer 62 through the slurry dispenser 205. The CMP slurry207 may also include rate inhibitors. The rate inhibitors may protectmaterials underlying the modified surface layer 62S. The rate inhibitorsincrease the removal rate difference between the modified surface layer62S and underlying materials (e.g., unmodified portions of the dummygate layer 62), and selection of the rate inhibitors depends on thematerial being altered. In an embodiment the CMP slurry 207 may compriseabrasives such as silica, alumina and ceria which will work inconjunction with the platen 203 to grind and remove the oxide layer.Because, as noted above, substantially no oxidation of the dummy gatelayer 62 occurs during the removal process, the CMP slurry 207 may besubstantially free of oxidants. After the removal of the oxidationlayer, the thickness of the dummy gate layer 62 may decrease by thethickness T₁. In some embodiments, the CMP slurry 207 may not be addedto the grinding process. The modified surface layer 62S may besufficiently weak that mechanical contact with the platen 203 issufficient to remove the modified surface layer 62S.

Once the oxide layer is removed from the substrate 50, the planarizationchamber 219 may be evacuated with a rinsing and spin-off operation, asdescribed above. The oxide formation and removal steps may then berepeated, with a purge between each removal, until a desired amount ofmaterial is removed from the top surface of the dummy gate layer 62.

Although the planarization process discussed above with respect to FIGS.8A, 8B, 8C, and 8D uses a self-limiting oxidation process with anoxidation solution, other embodiments may form the modified surfacelayer 62S through other means. In some embodiments, the oxidation may beaccomplished by dispensing a gas, such as O₃, over the substrate 50 witha showerhead. In some embodiments, a chemical bonding process may beused to introduce ligands or chelators that occupy surface molecules ofthe substrate 50, thereby forming a modified surface layer that may beremoved by the mechanical processes.

In embodiments where the self-limiting process is a chemical bondingprocess, the ligands are dispensed on the substrate 50 in a liquid form.In such embodiments, the ligands occupy surface bonds of the top surfaceof the wafer or substrate 50. The ligands bind to the surface, modifyingit, and thereby forming the modified surface layer 62S. The ligands maybe dispensed in a similar manner as the oxidation solution, e.g.,through the slurry dispenser 205. The ligands may be formed from some ofthe individual chemical components that make up the CMP slurry 207, suchas those delivered by the slurry delivery systems 213. In suchembodiments, the CMP slurry 207 may be supplied to the planarizationprocess as individual chemical components, instead of a premixed slurry,and the ligands may be selected from those chemical components anddispensed in pulses that bind to the wafer surface during theself-limiting process. The individual chemical components may beadjusted or selected to adjust the amount that the wafer surface ismodified.

Further although the planarization process discussed above with respectto FIGS. 8A, 8B, 8C, and 8D is described as performing multiple pulsesor cycles of oxidation and removal in the same planarization chamber219, it should be appreciated that more than one planarization chamber219 may be used. For example, two planarization chambers 219 may beused, where a first planarization chamber 219 is used for dispensing theoxidation solution on the substrate 50 to form the modified surfacelayer 62S, and a second planarization chamber 219 is used for removingthe modified surface layer 62S.

FIG. 8B illustrates an embodiment of the control unit 227 that may beutilized to control the oxidation reactant controller 224 and the pump239 (as illustrated in FIG. 8A). Control signals of the control unit 227are illustrated with dashed lines. The control unit 227 may be any formof computer processor that can be used in an industrial setting forcontrolling process machines. In an embodiment, the control unit 227comprises a processing unit 251, such as a desktop computer, aworkstation, a laptop computer, or a dedicated unit customized for aparticular application. The control unit 227 may be equipped with adisplay 253 and one or more input/output components 255, such asinstruction outputs, sensor inputs, a mouse, a keyboard, printer,combinations of these, or the like. The processing unit 251 may includea central processing unit (CPU) 257, memory 259, a mass storage device261, a video adapter 263, and an I/O interface 265 connected to a bus267.

The bus 267 may be one or more of any type of several bus architecturesincluding a memory bus or memory controller, a peripheral bus, or videobus. The CPU 257 may comprise any type of electronic data processor, andthe memory 259 may comprise any type of system memory, such as staticrandom access memory (SRAM), dynamic random access memory (DRAM), orread-only memory (ROM). The mass storage device 261 may comprise anytype of storage device configured to store data, programs, and otherinformation and to make the data, programs, and other informationaccessible via the bus 267. The mass storage device 261 may comprise,for example, one or more of a hard disk drive, a magnetic disk drive, oran optical disk drive.

The video adapter 263 and the I/O interface 265 provide interfaces tocouple external input and output devices to the processing unit 251. Asillustrated in FIG. 8B, examples of input and output devices include thedisplay 253 coupled to the video adapter 263 and the I/O component 255,such as a mouse, keyboard, printer, and the like, coupled to the I/Ointerface 265. Other devices may be coupled to the processing unit 251,and additional or fewer interface cards may be utilized. For example, aserial interface card (not shown) may be used to provide a serialinterface for a printer. The processing unit 251 also may include anetwork interface 269 that may be a wired link to a local area network(LAN) or a wide area network (WAN) 271 and/or a wireless link.

It should be noted that the control unit 227 may include othercomponents. For example, the control unit 227 may include powersupplies, cables, a motherboard, removable storage media, cases, and thelike. These other components, although not shown in FIG. 8B, areconsidered part of the control unit 227.

Although the planarization system 200 is shown as being used toplanarize the dummy gate layer 62, it should be appreciated that ALRwith the planarization system 200 could be performed to planarize a widevariety of materials. For example, in embodiments where a dielectric isto be planarized, such as the planarizing of the insulation material 54,ALR could be used, and the self-limiting process may be a chemicalbonding process.

Further, although the planarization system 200 is shown as being anorbital polishing planarization system, it should be appreciated thatembodiments may be applied in other types of planarization systems. Forexample, FIG. 8E illustrates aspects of the planarization system 200,according to some other embodiments. In the embodiment of FIG. 8E, thewafer carrier 201 is a polishing head, and the substrate 50 is fixed inthe polishing head such that it faces the platen 203 in a downwarddirection. A chuck 301 having the platen 203 thereon is rotated. Thewafer carrier 201 rotates the substrate 50 and provides downward forcesthat cause the substrate 50 to be pressed against the platen 203(including the polishing pad) as the substrate 50 and platen 203 rotate.The CMP slurry 207 is dispensed on the platen 203 by the slurrydispenser 205. During operation, a pad conditioner 303 is swept acrossthe platen 203 to increase surface roughness of the polishing pad andremove used CMP slurry 207. The pad conditioner 303 may be, e.g., astainless steel plate that is coated with abrasives such asnickel-plated diamond grits, a diamond film, or the like. An arm 305secures and moves the pad conditioner 303 during operation. In theembodiment shown in FIG. 8E, the self-limiting process may be performedby dispensing the oxidation solution on the platen 203 with the slurrydispenser 205. The substrate 50 may be exposed to the oxidation solutionon the platen 203 when downward forces are not applied by the wafercarrier 201 (e.g., polishing head). In some embodiments, the polishinghead and chuck 301 may not be rotated during the self-limiting process.After the self-limiting process completes, the substrate 50 is cleanedof the oxidation solution. The CMP slurry 207 is then dispensed and thesubstrate 50 is polished by rotating the polishing head and chuck 301while applying downward forces with the polishing head.

In FIG. 9, a mask layer 64 is formed over the dummy gate layer 62. Themask layer 64 may be deposited over the dummy gate layer 62. The masklayer 64 may include, for example, SiN, SiON, or the like. In theexample shown, a single dummy gate layer 62 and a single mask layer 64are formed across the first region 50B and the second region 50C. Insome embodiments, separate dummy gate layers may be formed in the firstregion 50B and the second region 50C, and separate mask layers may beformed in the first region 50B and the second region 50C.

In FIGS. 10A and 10B, the mask layer 64 may be patterned usingacceptable photolithography and etching techniques to form masks 74. Thepattern of the masks 74 then may be transferred to the dummy gate layer62 and the dummy dielectric layer 60 by an acceptable etching techniqueto form dummy gates 72. The dummy gates 72 cover respective channelregions of the fins 58. The dummy gates 72 may also have a lengthwisedirection substantially perpendicular to the lengthwise direction ofrespective epitaxial fins.

Further in FIGS. 10A and 10B, gate seal spacers 80 can be formed onexposed surfaces of the dummy gates 72, the masks 74, and/or the fins58. A thermal oxidation or a deposition followed by an anisotropic etchmay form the gate seal spacers 80. After the formation of the gate sealspacers 80, implants for lightly doped source/drain (LDD) regions 81 maybe performed. An anneal may be used to activate the implantedimpurities.

In FIGS. 11A and 11B epitaxial source/drain regions 82 are formed in thefins 58. The epitaxial source/drain regions 82 are formed in the fins 58such that each dummy gate 72 is disposed between respective neighboringpairs of the epitaxial source/drain regions 82. In some embodiments thatepitaxial source/drain regions 82 may extend into the fins 52. Theepitaxial source/drain regions 82 may be formed by masking the firstregion 50B, recessing the fins 58 in the second region 50C, epitaxiallygrowing the epitaxial source/drain regions 82 in the recesses, andremoving the mask. The second region 50C may be masked, and the processrepeated for the first region 50B.

In FIGS. 12A and 12B, gate spacers 86 are formed on the gate sealspacers 80 along sidewalls of the dummy gates 72 and the masks 74. Thegate spacers 86 may be formed by conformally depositing a material andsubsequently anisotropically etching the material. The material of thegate spacers 86 may be silicon nitride, SiCN, a combination thereof, orthe like.

The epitaxial source/drain regions 82 and/or the epitaxial fins may beimplanted with dopants to form source/drain regions, similar to theprocess previously discussed for forming lightly doped source/drainregions, followed by an anneal. The source/drain regions may have animpurity concentration of between about 10¹⁹ cm⁻³ and about 10²¹ cm⁻³.The n-type and/or p-type impurities for source/drain regions may be anyof the impurities previously discussed. In some embodiments, theepitaxial source/drain regions 82 may be in situ doped during growth.

In FIGS. 13A and 13B, an ILD 88 is deposited over the substrate 50. TheILD 88 may be formed of a dielectric material, and may be deposited byany suitable method, such as CVD, plasma-enhanced CVD (PECVD), or FCVD.Dielectric materials may include Phospho-Silicate Glass (PSG),Boro-Silicate Glass (BSG), Boron-Doped Phospho-Silicate Glass (BPSG),undoped Silicate Glass (USG), or the like. Other insulation orsemiconductor materials formed by any acceptable process may be used.

In FIGS. 14A and 14B, a planarization process, such as a CMP, may beperformed to level the top surface of the ILD 88 with the top surfacesof the dummy gates 72. In an embodiment, the planarization process is anALR process performed using the planarization system 200. Theplanarization process may also remove the masks 74 on the dummy gates72, and portions of the gate seal spacers 80 and the gate spacers 86along sidewalls of the masks 74. After the planarization process, topsurfaces of the dummy gates 72, the gate seal spacers 80, the gatespacers 86, and the ILD 88 are level. Accordingly, the top surfaces ofthe dummy gates 72 are exposed through the ILD 88.

In FIGS. 15A and 15B, the exposed portions of the dummy gates 72, thegate seal spacers 80, and portions of the dummy dielectric layer 60directly underlying the exposed dummy gates 72 are removed in an etchingstep(s), so that recesses 90 are formed. In some embodiments, the dummygates 72 are removed by an anisotropic dry etch process. For example,the etching process may include a dry etch process using reactiongas(es) that selectively etch the dummy gates 72 without etching the ILD88 or the gate spacers 86. Each recess 90 exposes a channel region of arespective fin 58. Each channel region is disposed between neighboringpairs of the epitaxial source/drain regions 82. During the removal, thedummy dielectric layer 60 may be used as an etch stop layer when thedummy gates 72 are etched. The dummy dielectric layer 60 and the gateseal spacers 80 may then be removed after the removal of the dummy gates72.

In FIGS. 16A and 16B, gate dielectric layers 92 and gate electrodes 94are formed for replacement gates. Gate dielectric layers 92 aredeposited conformally in the recesses 90, such as on the top surfacesand the sidewalls of the fins 58 and on sidewalls of the gate spacers86, and on a top surface of the ILD 88. According to some embodiments,the gate dielectric layers 92 are silicon oxide, silicon nitride, ormultilayers thereof. In some embodiments, the gate dielectric layers 92are a high-k dielectric material, and in these embodiments, the gatedielectric layers 92 may have a k value greater than about 7.0, and mayinclude a metal oxide or a silicate of Hf, Al, Zr, La, Mg, Ba, Ti, Pb,and combinations thereof. The formation methods of the gate dielectriclayers 92 may include Molecular-Beam Deposition (MBD), ALD, PECVD, andthe like.

The gate electrodes 94 are deposited over the gate dielectric layers 92,respectively, and fill the remaining portions of the recesses 90. Thegate electrodes 94 may be a metal-containing material such as TiN, TaN,TaC, Co, W, Ru, Al, combinations thereof, or multi-layers thereof. Afterthe filling of the gate electrodes 94, a planarization process, such asa CMP, may be performed to remove the excess portions of the gatedielectric layers 92 and the material of the gate electrodes 94, whichexcess portions are over the top surface of the ILD 88. In anembodiment, the planarization process is an ALR process performed usingthe planarization system 200.

The resulting remaining portions of material of the gate electrodes 94and the gate dielectric layers 92 thus form replacement gates of theresulting FinFETs. The gate electrodes 94 and the gate dielectric layers92 may be collectively referred to as a “gate” or a “gate stack.”

The formation of the gate dielectric layers 92 in the first region 50Band the second region 50C may occur simultaneously such that the gatedielectric layers 92 in each region are formed from the same materials,and the formation of the gate electrodes 94 may occur simultaneouslysuch that the gate electrodes 94 in each region are formed from the samematerials. In some embodiments, the gate dielectric layers 92 in eachregion may be formed by distinct processes, such that the gatedielectric layers 92 may be different materials, and the gate electrodes94 in each region may be formed by distinct processes, such that thegate electrodes 94 may be different materials. Various masking steps maybe used to mask and expose appropriate regions when using distinctprocesses.

In FIGS. 17A and 17B, an ILD 108 is deposited over the ILD 88. In anembodiment, the ILD 108 is a flowable film formed by a flowable CVDmethod. In some embodiments, the ILD 108 is formed of a dielectricmaterial such as PSG, BSG, BPSG, USG, or the like, and may be depositedby any suitable method, such as CVD and PECVD. Because variousembodiments allow use of a planarization stop layer to be avoided, theILD 108 may physically contact the ILD 88.

In FIGS. 18A and 18B, contacts 110 and 112 are formed through the ILD108 and the ILD 88. Openings for the contacts 110 and 112 are formedthrough the ILD 108 and the ILD 88. These openings may all be formedsimultaneously in a same process, or in separate processes. The openingsmay be formed using acceptable photolithography and etching techniques.A liner, such as a diffusion barrier layer, an adhesion layer, or thelike, and a conductive material are formed in the openings. The linermay include titanium, titanium nitride, tantalum, tantalum nitride, orthe like. The conductive material may be copper, a copper alloy, silver,gold, tungsten, aluminum, nickel, or the like. A planarization process,such as a CMP, may be performed to remove excess material from a surfaceof the ILD 108. In an embodiment, the planarization process is an ALRprocess performed using the planarization system 200. The remainingliner and conductive material form the contacts 110 and 112 in theopenings. An anneal process may be performed to form a silicide at theinterface between the epitaxial source/drain regions 82 and the contacts112. The contact 110 is physically and electrically connected to thegate electrode 94, and the contacts 112 are physically and electricallyconnected to the epitaxial source/drain regions 82.

Embodiments may achieve advantages. Oxidizing a surface of the wafer,such as the dummy gate layer 62, may allow a self-limiting process to beemployed during planarization. As such, the thickness of the materialremoved by the planarization may be controlled such that a predeterminedamount of material may be removed without the use of stop layers.Further, the time and material costs associated with some techniquesused to rework variances in planarization rates may be avoided.

In an embodiment, a method includes: performing a self-limiting processto modify a top surface of a wafer; after the self-limiting processcompletes, removing the modified top surface from the wafer; andrepeating the performing the self-limiting process and the removing themodified top surface from the wafer until a thickness of the wafer isdecreased to a predetermined thickness.

In some embodiments, the self-limiting process occupies surface bonds ofthe top surface of the wafer with ligand molecules. In some embodiments,the self-limiting process is an oxidation process. In some embodiments,the oxidation process includes exposing the top surface of the wafer to0 ₃. In some embodiments, the 0 ₃ is dispensed with a slurry dispenser.In some embodiments, the oxidation process includes dispensing anoxidation solution on the top surface of the wafer, the oxidationsolution including H₂O₂ or Fe(NO₃)₃. In some embodiments, the H₂O₂ isdispensed with a slurry dispenser. In some embodiments, a slurry isdispensed on the wafer with the slurry dispenser during the removing themodified top surface from the wafer. In some embodiments, a plurality ofchemicals are connected to the slurry dispenser, and the dispensing theH₂O₂ includes selecting one or more of the chemicals and dispensing theselected chemicals with the slurry dispenser. In some embodiments, nofurther modification of the top surface of the wafer is performed duringthe removing the modified top surface from the wafer.

In an embodiment, a method includes: forming fins on a substrate;forming a dummy gate material over the fins; oxidizing a top surface ofthe dummy gate material to form an oxide layer in the top surface of thedummy gate material, the oxidizing performed until a predefined amountof time elapses; after the oxidizing the top surface of the dummy gatematerial, removing the oxide layer from the dummy gate material;patterning the dummy gate material to form a dummy gate; forming gatespacers along sides of the dummy gate; and replacing the dummy gate witha replacement gate dielectric and a replacement gate electrode.

In some embodiments, the top surface of the dummy gate material isoxidized with a self-limiting process, and substantially no oxidizing ofthe dummy gate material is performed during the removing the oxidelayer. In some embodiments, the oxidizing the top surface of the dummygate material is performed for a timespan of from about 1 second to 30seconds. In some embodiments, the oxidizing the top surface of the dummygate material is performed until the thickness of the oxide layer isfrom about 2 to 50. In some embodiments, the removing the oxide layerfrom the dummy gate material includes: dispensing a slurry on the topsurface of the dummy gate material; and grinding the top surface of thedummy gate material while dispensing the slurry. In some embodiments,the slurry is dispensed through a slurry dispenser, and the oxidizingthe top surface of the dummy gate material includes dispensing H₂O₂ withthe slurry dispenser.

In an embodiment, a method includes: mixing a first subset of aplurality of chemicals to produce an oxidation solution; dispensing theoxidation solution on a top surface of a wafer; stopping the dispensingof the oxidation solution; after the stopping the dispensing of theoxidation solution, mixing a second subset of the plurality of chemicalsto produce an abrasive solution; and dispensing the abrasive solution onthe top surface of the wafer while grinding the top surface of thewafer.

In some embodiments, the oxidation solution converts the top surface ofthe wafer to an oxidized layer, and the dispensing of the oxidationsolution is stopped after a thickness of the oxide layer stopsincreasing. In some embodiments, the method further includes: before themixing a second subset of the plurality of chemicals to produce anabrasive solution, rinsing the oxidation solution from the top surfaceof a wafer. In some embodiments, the abrasive solution includes one ormore of silica, alumina, or ceria, the abrasive solution furtherincludes rate inhibitors, and the abrasive solution is free of oxidationreactants.

The foregoing outlines features of several embodiments so that thoseskilled in the art may better understand the aspects of the presentdisclosure. Those skilled in the art should appreciate that they mayreadily use the present disclosure as a basis for designing or modifyingother processes and structures for carrying out the same purposes and/orachieving the same advantages of the embodiments introduced herein.Those skilled in the art should also realize that such equivalentconstructions do not depart from the spirit and scope of the presentdisclosure, and that they may make various changes, substitutions, andalterations herein without departing from the spirit and scope of thepresent disclosure.

What is claimed is:
 1. A method comprising: performing a self-limitingprocess to modify a top surface of a wafer; after the self-limitingprocess completes, removing the modified top surface from the wafer; andrepeating the performing the self-limiting process and the removing themodified top surface from the wafer until a thickness of the wafer isdecreased to a predetermined thickness.
 2. The method of claim 1,wherein the self-limiting process occupies surface bonds of the topsurface of the wafer with ligand molecules.
 3. The method of claim 1,wherein the self-limiting process is an oxidation process.
 4. The methodof claim 3, wherein the oxidation process comprises exposing the topsurface of the wafer to O₃.
 5. The method of claim 4, wherein the O₃ isdispensed with a slurry dispenser.
 6. The method of claim 3, wherein theoxidation process comprises dispensing an oxidation solution on the topsurface of the wafer, the oxidation solution including H₂O₂ or Fe(NO₃)₃.7. The method of claim 6, wherein the H₂O₂ is dispensed with a slurrydispenser.
 8. The method of claim 7, wherein a slurry is dispensed onthe wafer with the slurry dispenser during the removing the modified topsurface from the wafer.
 9. The method of claim 7, wherein a plurality ofchemicals are connected to the slurry dispenser, and wherein thedispensing the H₂O₂ comprises selecting one or more of the chemicals anddispensing the selected chemicals with the slurry dispenser.
 10. Themethod of claim 1, wherein no further modification of the top surface ofthe wafer is performed during the removing the modified top surface fromthe wafer.
 11. A method comprising: forming fins on a substrate; forminga dummy gate material over the fins; oxidizing a top surface of thedummy gate material to form an oxide layer in the top surface of thedummy gate material, the oxidizing performed until a predefined amountof time elapses; after the oxidizing the top surface of the dummy gatematerial, removing the oxide layer from the dummy gate material;patterning the dummy gate material to form a dummy gate; forming gatespacers along sides of the dummy gate; and replacing the dummy gate witha replacement gate dielectric and a replacement gate electrode.
 12. Themethod of claim 11, wherein the top surface of the dummy gate materialis oxidized with a self-limiting process, and wherein substantially nooxidizing of the dummy gate material is performed during the removingthe oxide layer.
 13. The method of claim 12, wherein the oxidizing thetop surface of the dummy gate material is performed for a timespan offrom about 1 second to 30 seconds.
 14. The method of claim 12, whereinthe oxidizing the top surface of the dummy gate material is performeduntil the thickness of the oxide layer is from about 2 Å to 50 Å. 15.The method of claim 11, wherein the removing the oxide layer from thedummy gate material comprises: dispensing a slurry on the top surface ofthe dummy gate material; and grinding the top surface of the dummy gatematerial while dispensing the slurry.
 16. The method of claim 15,wherein the slurry is dispensed through a slurry dispenser, and whereinthe oxidizing the top surface of the dummy gate material comprisesdispensing H₂O₂ with the slurry dispenser.
 17. A method comprising:mixing a first subset of a plurality of chemicals to produce anoxidation solution; dispensing the oxidation solution on a top surfaceof a wafer; stopping the dispensing of the oxidation solution; after thestopping the dispensing of the oxidation solution, mixing a secondsubset of the plurality of chemicals to produce an abrasive solution;and dispensing the abrasive solution on the top surface of the waferwhile grinding the top surface of the wafer.
 18. The method of claim 17,wherein the oxidation solution converts the top surface of the wafer toan oxidized layer, and wherein the dispensing of the oxidation solutionis stopped after a thickness of the oxide layer stops increasing. 19.The method of claim 17, further comprising: before the mixing a secondsubset of the plurality of chemicals to produce an abrasive solution,rinsing the oxidation solution from the top surface of a wafer.
 20. Themethod of claim 17, wherein the abrasive solution includes one or moreof silica, alumina, or ceria, wherein the abrasive solution furtherincludes rate inhibitors, and wherein the abrasive solution is free ofoxidation reactants.